Compressed Foam Barrier Assembly for Gas Water Heater Insulation
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Solution Overview
Problem
Existing gas-fueled water heater appliances face challenges in consistently installing effective insulation barriers between the tank and combustion chamber due to the high temperatures and complexities in handling and distributing foam materials, leading to inconsistent foam distribution and poor insulation.
Innovation Solution
A method and system involving a compressed foam barrier circumferentially positioned around the tank, with a covering extending over it, where the foam barrier is decompressed to seal against the covering, creating separate sections, and foam material is injected into one section to form a barrier around the tank's outer surface, preventing entry into the other section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid foam is injected into a belt-bag wrapper around the tank, then insulation barrier is formed, but installation timing becomes critical and difficult to achieve
Solution Approach 1:
The foam is pre-compressed into a compact barrier before installation. This preliminary compression allows the foam to be easily positioned around the tank without requiring critical timing during injection, as the foam maintains its compressed state until decompression is intentionally triggered
Solution Approach 2:
The foam barrier transitions from a compressed state during installation to an expanded state after installation. This dynamic state change allows for easy handling and positioning during installation, then automatic expansion to form the insulation barrier after the covering is in place
2Ease of manufacture
If a donut-shaped foam material is rolled over the tank, then covering can be placed, but final position becomes inconsistent with each installation
Solution Approach 1:
The foam is pre-compressed into a consistent, compact form that maintains its shape and position during installation. This preliminary compression ensures uniform dimensions and positioning, eliminating the inconsistency that occurs when foam is rolled into place
Solution Approach 2:
The foam barrier is positioned at a specific location around the tank with precise control over its placement. The compressed foam maintains its local position consistently, ensuring uniform insulation coverage rather than allowing gravitational rolling to displace it
3Reliability
If foam is injected into a large plastic bag before covering assembly, then barrier is formed, but poor foam distribution occurs due to kinks and traps
Solution Approach 1:
The foam is contained within a flexible compressed structure that can be easily positioned and sealed around the tank. This flexible compressed form prevents kinks and traps that occur with large plastic bags, ensuring uniform foam distribution through controlled decompression
Solution Approach 2:
The foam is pre-compressed into a uniform, trap-free configuration before installation. This preliminary compression eliminates air pockets and kinks that would cause poor distribution, ensuring smooth and uniform foam expansion after installation
4Reliability
If standard water heater insulating foam is used in the combustion chamber, then insulation is provided, but foam cannot withstand high temperatures
Solution Approach 1:
The insulation system is divided into two separate sections: a compressed foam barrier that provides structural support and positioning, and an insulating foam material that provides thermal insulation. This segmentation allows each component to perform its optimal function without being exposed to temperatures it cannot withstand
Solution Approach 2:
The compressed foam barrier acts as an intermediary structure between the tank and the insulating foam material. It provides a stable framework that positions the insulation material correctly while protecting it from direct exposure to high combustion chamber temperatures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures consistent and effective insulation by maintaining the foam barrier around the tank's outer surface, enhancing thermal separation and improving energy efficiency while simplifying the installation process by eliminating the need for rushed assembly and reducing kinks or traps in foam distribution.
Implementation Method 1
The foam barrier prevents the foam material from entering the second section of the internal volume
Implementation Method 2
decompressing the compressed foam barrier such that an outer diameter of the compressed foam barrier expands
Data Source
AI summary
A method for insulating a gas-fueled water heater includes providing a tank for storage of water for heating and a combustion chamber adjacent to the tank. The method includes providing a compressed foam barrier circumferentially around the tank. Further, the method includes positioning a covering around the tank from a top end to a bottom end, the covering extending over the compressed foam barrier. Moreover, the method includes decompressing the compressed foam barrier such that an outer diameter of the foam barrier expands up to and seals against the covering so as to separate an internal volume defined between an outer surface of the tank and the covering into a first section and a second section. Then, the method includes injecting a foam material into the first section so as to provide a foam barrier around at least a portion of an outer surface of the tank.